DS350G Boom Control Service AC 120

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DS350G BCS
(5-SECT. BOOM)
SERVICE MANUAL (TMS/TTS870, RT865BXL)
031-300-190-039 Rev. D 2/16/06 190039_D

DS 350 G Boom Control Troubleshooting- TMS/TTS870 / RT865 BXL
NOTICE
Hirschmann Electronics, Inc. makes no warranty of any kind with regard to this material,
including, but not limited to, the implied warranties of merchantability and/or its fitness for a
particular purpose.
Hirschmann Electronics, Inc. will not be liable for errors contained in this manual or for
incidental or consequential damages in connection with the furnishing, performance, or use of
this manual. This document contains proprietary information, which is protected by copyright,
and all rights are reserved.
No part of this document may be photocopied, reproduced, or translated to another language

without the prior written consent of Hirschmann Electronics, Inc.
Hirschmann Electronics, Inc. reserves proprietary rights to all drawings, photos and the data
contained therein. The drawings, photos and data are confidential and cannot be used or
reproduced without the written consent of Hirschmann Electronics, Inc. The drawings and/or
photos are subject to technical modification without prior notice.
All information in this document is subject to change without notice.
MANUAL REVISIONS
REV DATE NAME DESCRIPTION

C 08/18/03 CSH ECN 03-095
D 02/16/06 SB ECN 06-013
031-300-190-039 Rev. D 2/16/06 190039_D

TABLE OF CONTENTS
Section Content Page
1 General Information 1
2 Reference Material 1
3 Warnings 1
4 Service and Maintenance 2
5 Boom Control Interface 3
6 Boom Sequence 8
7 Boom Control Flow 9
8 Ramping 11
9.1 DS 350 G - Boom Components and Setup 12
9.2 Length Transducer Adjustment 14
9.3 DS 350 G - Superstructure Components - TMS/ TTS 870 15
9.4 DS 350 G - Superstructure Components - RT 865 BXL 16
10.1 DS350 G LMI Central unit (751) - TMS/ TTS 870 & RT 865 BXL 17
10.2 LMI Terminal board - TMS/ TTS 870 & RT 865 BXL 18
11.1 Wiring Schematic - TMS/ TTS 870 19
11.2 Wiring Schematic - RT 865 BXL 24
12 Boom Length Percentage Error 28
13 Main Boom Length Error 36
14 Inner Mid Length Error 42
15 Center Mid Length Error 48
16 No Extend or Retract Function in Automode 54
17 Out of Sequence Warning 56
18 Error Codes 61
031-300-190-039 Rev. D 2/16/06 190039_D

DS 350 G Boom Control Troubleshooting- TMS/TTS870 / RT865 BXL 1
1. General Information
The DS 350 load moment indicator (LMI) with boom control extension is designed to aid the
crane operator through the crane operations. The DS 350 with boom control extension is not,
and shall not, be a substitute for good operator judgment, experience and use of accepted
safe crane operating procedure.
2. Reference Material
Parts & Installation Manual:
Crane Model PAT- Part number Grove- Part number

TMS/ TTS 870 031-300-150-662 9-333-103129
RT 865 BXL 031-300-150-659 9-333-103206
Operator’s Handbook:
PAT - Part number

50\350\19_1319e.doc
3. Warnings
The DS 350 load moment indicator (LMI) with boom control extension is an operational aid
that warns the crane operator when he approaches an overload condition, a two block
condition and an out of boom sequence condition. The boom control extension controls the
sequence of the boom during operation. It still remains the operator’s responsibility to verify
the operation and to select the correct mode during crane operations.
The manual mode is a rigging mode. Lifting loads with manual mode programmed is
prohibited.
Should an out of sequence condition occur, the crane operator is responsible to select
manual mode to return the sections into sequence before continuing the lift.
The responsibility for safe crane operation shall remain with the crane operator who shall
ensure that all warnings and instructions supplied are fully understood and observed.
Prior to operating the crane, the operator must carefully and thoroughly read and understand
the information provided by the crane and load moment indicator manufacturer.
Proper functioning depends upon proper daily inspection and observance of the operating
instructions provided with the crane and load moment indicator.
031-300-190-039 Rev. D 2/16/06 190039_D

4. Service and Maintenance
Daily maintenance of the load moment indicator consists of inspecting:
1. The electrical wiring connecting the various parts of the system.

If electrical wiring is damaged, it shall be replaced immediately.
2. If the insulation is worn on the length sensor cable or cable guides are damaged, these
parts shall be replaced.
3. Check the anti two-block limit switches for freedom of movement.
4. The cable reel shall be under tension to operate properly.
5. Check the pressure transducers at the hoist cylinder(s) and the connecting hoses for oil
leakage.
Other than correcting the problems identified in the Malfunctions Table and replacing faulty
mechanical parts and cables, no other repairs shall be performed by non expert personnel.
031-300-190-039 Rev. D 2/16/06 190039_D

Automode A selector switch
House lock switch (EEC units) *
Drawing 1.
Boom extend P-switch extend pilot pressure
DI 1
Boom retract P-switch retract pilot pressure
DI 2
connector
Auto mode on
DI 3
Crane interface
Automode switch in cabin
House lock engaged
DI 7
Auto mode A *
Front O/R pressure switch
DI 8
031-300-190-039 Rev. D 2/16/06

Digital Front O/R overloaded
DI 9
Input OM/Fly retracted & 0% Prox.switch on CM section
DI 4
Inner mid retracted
5. Boom Control Interface
DI 5
technical modification without prior notice.

Prox.switch on base section
Inner mid 0%
DI 6 Prox.switch on base section
Center mid retracted & 0%
DI 11 Prox.switch on IM section
Area def. switch *
IM 2- way valve
Boom K2 2- way valves (inner mid)
Rod side dump
control valve
LMI Circuit K3 Rod side dump valve
circuit Tele out of
K4 sequence
Out of sequence warning light
Proportional
K5 output / retract pressure reducing valve/
Relays
Proportional connector retract
Crane interface
output K5 output / extend pressure reducing valve/
extend
CM 2- way valve
K6 2- way valves (center mid)
OM 2- way valve
K7 2- way valves (outer mid)
K5
Prop.
Analog output
Inner mid length sensor

Analog input
Center mid length sensor
Main boom length sensor
Main boom angle sensor

Rod pressure transducer
Piston pressure transducer
870 - LMI (751)
PAT Equipment Corporation reserves proprietary rights to this drawing and to the data shown there on. The drawing and data are
* = RT 865BXL only
LMI Console
confidential and are not to be used or reproduced without the written consent of PAT Equipment Corporation. This drawing is subject to
190039_D
3
Auto mode / Manual mode:

The operator selects auto mode or manual mode using the rocker switch in the dash board.
Auto mode is the working mode and manual mode is used for rigging or sequencing purpose
only.
Pilot pressure switch signal / Analog output signal:

Two pressure switches in the pilot pressure circuit are used to distinguish between boom
extend or boom retract. The two circuits are wired through the crane interface connector into
the DS 350 G central unit.
When the operator extends the boom, the pressure switch signal at central unit terminal
A101-X1/38 changes from 0V to +24V. The boom control logic allows electrical current to flow
to the extend pressure reducing valve coil. The minimum current equals 0 mA with the control
in neutral position. The maximum current output equals 800 mA.
To measure the coil current while extending, remove wire #20from central unit terminal
A101-X1/63. Connect the Amp-meter in series with wire #20 to terminal X1/63.
When the operator retracts the boom, the pressure switch signal at central unit terminal
A101-X1/40 changes from 0V to +24V. The boom control logic allows electrical current to flow
to the retract pressure reducing valve coil. The minimum current equals 0 mA with the control
in neutral position. The maximum current output equals 800 mA.
To measure the coil current while retracting, remove wire #21 from central unit terminal
A101-X1/64. Connect the Amp-meter in series with wire #21 to terminal X1/64.
031-300-190-039 Rev. D 2/16/06 190039_D

Length sensors:
Three length sensors are mounted to the boom base section to measure the overall length,
the inner mid section length and the center mid section length. The software utilizes the
signals to calculate the outer mid and fly section length.
Disengage the boom stop to retract the boom completely.
With retracted main boom the overall boom length signal is -500 mV (A101-X1/10). Use the
test pin MP 15 (AGND) or terminal A101-X1/8 (AGND) for reference ground. Disengage the
boom stop to retract the boom completely.
With retracted main boom the inner mid section length signal is -500 mV (A101-X1/24). Use
the test pin MP 15 (AGND) or terminal A101-X1/8 (AGND) for reference ground.
With retracted main boom the center mid section length signal is -500 mV (A101-X1/73). Use
the test pin MP 15 (AGND) or terminal A101-X1/8 (AGND) for reference ground.
Keep the cable on the length transducer drum spooled properly. A poorly spooled cable may causes the boom
to become out of sequence. If the boom becomes out of sequence, select manual mode and correct the length
by operating individual sections. Once the sections are sequenced again the operator may return to the
automode. Refer to section 9.1 for boom components installation and set up.
Inner mid retract and % reset switch:

The reset- proximity switch on the base section provides a (+24V) signal to central unit
terminal A 104 X1/80 when the inner mid section is retracted against the boom stop. The
signal resets the inner mid percentage to 1%.
The retract- proximity switch on the base section provides a (+24V) signal to central unit
terminal A 104 X1/78 when the inner mid section is fully retracted (disengage the boom stop).
031-300-190-039 Rev. D 2/16/06 190039_D

Center mid retract and % reset switch:

The proximity switch on the inner mid section provides a (+24V) signal to central unit terminal
A 114 X1/9 when the center mid section is fully retracted. The signal resets the center mid
percentage to 0%.
Refer to Parts & Installation Manual and follow the installation instructions for switch and target adjustment.
Outer mid/ fly retract and % reset switch:

The proximity switch on the center mid section provides a (+24V) signal to central unit
terminal A 114 X1/76 when the outer mid and fly section is fully retracted. The signal resets
the outer mid/ fly percentage to 0%.
Refer to Parts & Installation Manual and follow the installation instructions for switch and target adjustment.
System inputs:
DI # Description Central Unit Signal

Terminal (DI=on)
1 MB Pressure switch - boom extend A104 - X1/38 +24V
GND A104 - X1/37 0V
2 MB Pressure switch -boom retract A104 - X1/40 +24V
GND A104 - X1/39 0V
3 MB Automode switched on A104 - X1/42 +24V
GND A104 - X1/41 0V
4 MB Outer mid/ fly retract and % switch A104 - X1/76 +24V
GND A104 - X1/75 0V
5 MB Inner mid retract switch A104 - X1/78 +24V
GND A104 - X1/77 0V
6 MB Inner mid % reset switch A104 - X1/80 +24V
GND A104 - X1/79 0V
1 EX House lock engaged (RT 865 BXL-- Europe) * A114 - X1/1 +24V
GND A114 - X1/2 0V
2 EX Automode A = on; Automode B = off * A114 - X1/3 +24V
GND A114 - X1/4 0V
3 EX + Ub (24V) A114 - X1/5 +24V
Front outrigger overload (GND) A114 - X1/6 0V
4 EX Area def. switch (RT 865 BXL) * A114 - X1/7 +24V
GND A114 - X1/8 0V
5 EX Center mid retract and % reset switch A114 - X1/9 +24V
GND A114 - X1/10 0V
Note: MB = main board * = RT 865 BXL only

EX = extension board
031-300-190-039 Rev. D 2/16/06 190039_D

Output for two- way valves:
A pair of two- way valves controls the oil to each tele- cylinder. The relay output K2, K6, K7
operates the pair of two- way valves in automode. The valve need to be de-energized to
operate the particular cylinder. The valves for the sections that are not selected are powered
to prevent movement of the other cylinders.
Mode Relay K2 IM 2 way Relay K6 CM 2 way Relay K7 OM 2 way

[V] valves [V] valves [V] valves
A104-X1/54 A104-X1/66 A104-X1/69
Auto IM 0 0 24 1 24 1
Auto CM 24 1 0 0 24 1
Auto OM 24 1 24 1 0 0
Manual IM 0 0* 0 1* 0 1*
Manual CM 0 1* 0 0* 0 1*
Manual OM 0 1* 0 1* 0 0*
Error (Auto) 24 1 24 1 24 1
Neutral (Auto) 24 1 24 1 24 1
Note: * = powered directly from the section selector switch in the cabin.
Relay outputs:
Relay Fuse Description Central Unit Signal

Terminal
K1 F2 not used
not used
K2 F3 Inner mid two way- valves A104 - X1/54 +24V
GND A104 - X1/3 0V
K3 F4 Rod side dump valve A104 - X1/57 +24V
GND A104 - X1/3 0V
K4 F5 Tele out of sequence - Warning light in cabin A104 - X1/61 +24V
GND A104 - X1/3 0V
K5 F6 Signal from analog output board A104 - X1/62 0-800mA
K5 Directs the analog signal to the extend valve A104 - X1/63 0-800mA
K5 Directs the analog signal to the retract valve A104 - X1/64 0-800mA
K6 F7 Center mid two way- valves A104 - X1/66 +24V
K6 GND A104 - X1/3 0V
K7 F8 Outer mid two way- valves A104 - X1/69 + 24V
GND A104 - X1/3 0V
K8 none Internal LMI use (overload, error) A104 - X1/44 + 24V
K9 none Internal LMI use (A2B) A104 - X1/46 + 24V
K10 external Motion cut (Bosch relay) A104 - X1/48 + 24V
031-300-190-039 Rev. D 2/16/06 190039_D

Rod side dump valve:
Relay K3 controls the rod side dump valve. The valve dumps the rod side pressure when the
controller is in neutral position and during the time the section stops while changing over to
another section.
Controller Relay K3
A101 x1/ 57
Extend on 0V
Retract on 0V
Neutral +24V
Retracted/ retract on +24V
6. Boom Sequence
Main Boom:
Mode IM % CM % OM % FLY %
Auto B 0 0 0 0
Auto B 50 0 0 0
Auto B 50 50 0 0
Auto B 75 50 0 0
Auto B 75 75 0 0
Auto B 100 75 0 0
Auto B 100 100 0 0
Auto B 100 100 100 100
Auto A * 0 0 0 0
Auto A * 0 100 0 0
Auto A * 0 100 100 100
Auto A * 100 100 100 100
*= Mode A not available on RT 865 BXL
Extensions:
Auto 0 0 0 0
Auto 100 0 0 0
Auto 100 100 0 0
Auto 100 100 100 100
031-300-190-039 Rev. D 2/16/06 190039_D

7. Boom Control Flow
Operator moves
controller to extend or
retract position.
Directional pressure
switch transmits signal
to B.C.S.
B.C.S. checks input for Operation in manual

off
Automode. mode.
on
B.C.S. checks input for

A mode or B mode.
Console displays
length and % of each
B.C.S. checks the section.
correct
retract and % reset
switch and boom
length. Refer to section
B.C.S. defaults into a
6 for sequencing
incorrect rigging mode, console
information.
displays error code or
dashboard warning
light indicates "out of
sequence". Refer to
continue on next section 16 for BCS
page error codes
Drawing 2a.
031-300-190-039 Rev. D 2/16/06 190039_D

Continuation
The B.C.S. relays K2,

K6, K7 provide power
to the 2 way valves
allowing oil flow to the
selected cylinder.
The B.C.S. relay K3

controls the rod side
dump valve. Refer to
section 5.
The B.C.S. analog

output signal opens the
pressure reducing
valves (proportional
valves).
While estending and

retracting the B.C.S.
incorrect
monitors each section
length.
correct
Out of sequence warning and lock

The B.C.S. controls the out.Operate in manual mode to re-
speed and sequence of each sequence the boom. Reference
boom section. section 9.1 for boom components
and setup.
Drawing 2b.
031-300-190-039 Rev. D 2/16/06 190039_D

8. Ramping
Max. Ramp Ramp down Max. Ramp

Ramp
Value Value
Value
Ramp up
Min. Ramp Boom

Boom
Value Section B
Section A
-e.g. CM-
-e.g. IM-
Boom
Drawing 3. Change
Length
Over
Ramp value: A hex value in the software which determines the output current to the proportional valve.
Max. ramp value: The maximum hex value (hex 255) equals to 800 mA valve (pressure reducing valve). This
current is required to open the valve for maximum tele speed.
Min. ramp value: The minimum hex value that is required to move a section in the ramping area. These values
may differ for each ramping area.
Change over: The previous section comes to a complete stop and the next section ramps up (accelerates
speed).
IM: Inner Mid Section

CM: Center Mid Section
OM/Fly: Outer Mid Section & Fly
031-300-190-039 Rev. D 2/16/06 190039_D

9.1 DS 350 G - Boom Components and Setup
Center mid
4 length and
Inner mid length angle sensor
Inner mid % 8/9 LWG 221
sensor LG 221
reset switch
3 5 1
7
4 2
7 Overall boom
Center mid Inner mid length sensor
retract and % retract switch LG 208
reset switch
Outer mid
retract and %
reset switch
Drawing 4.
1. Pre-tension the cable reel spring by rotating drum (16) revolution counterclockwise. If replacing the LG 208
un-spool the length cable and secure to bushing on the boom nose as noted in the installation drawing.
Zero the length potentiometer as described on page 18.
2. Pre-tension the cable reel spring by rotating drum (35) revolution counterclockwise. If replacing the LG 221
un-spool the length cable and secure to bushing on the boom nose as noted in the installation drawing.
3. Pre-tension the cable reel spring by rotating drum (30) revolution counterclockwise. If replacing the LWG
221 un-spool the length cable and secure to bushing on the boom nose as noted in the installation drawing.
4. Run cable through the cable guides. Remove 1/4-20 nuts on bottom of cable guide, insert cable guide
screws through existing angle bracket and secure in place with 1/4-20 nuts removed previously.
5. Center line of cable must be aligned with center line of cable drum. See partial top view.
031-300-190-039 Rev. D 2/16/06 190039_D

1. Place tie wrap, 120 degree apart around the bushing. Wrap cable (8-10) revolutions over the tie wraps
starting from the outside and working inward. Allow ample cable to reach the junction box. Secure with (2)
additional tie wraps. See page 17.
2. Check proximity switch installation (0.44 inch from target) when boom sections are fully retracted.
3. This target is only installed if the boom is equipped with a boom extension stop block.
4. Check this proximity switch installation (0.13 inch from target) when boom sections are fully retracted.
This proximity
switch is used to
This proximity reset the inner mid
switch is used to percentage.
sense the center
mid section fully 0.44”
retracted. 0.44”
Partial top view
0.44”
3.94”
1.34”
This proximity switch

To be aligned is used to sense the
with center line inner mid section fully
of cable reel retracted.
6 drum.
Drawing 5.
031-300-190-039 Rev. D 2/16/06 190039_D

9.2 Length Transducer Adjustment
Drawing 6.
031-300-190-039 Rev. D 2/16/06 190039_D

9.3 DS 350 G Superstructure Components - TMS/TTS 870
Drawing 7.
031-300-190-039 Rev. D 2/16/06 190039_D

9.4 DS 350 G Superstructure Components - RT 865 BXL
Drawing 8.
031-300-190-039 Rev. D 2/16/06 190039_D

10.1 DS 350 G LMI central unit (751) - TMS/TTS 870 & RT 865 BXL
Diode extension Real time clock (Timer board)
board with e-prom sockets
Diode extension Key to open central unit

board enclosure
Analog output 3rd wrap warning Digital input Decoder board Termial board
extension board relay board extension board
Drawing 9.
031-300-190-039 Rev. D 2/16/06 190039_D

10.2 LMI Terminal board - TMS 870, TTS 870 and RT 865 BXL
X1
X1
X1
F8
F7
F6 K6
F5
K5 K7
F4
X1
F3 K3
F2
K4
K2
X1 K1
K9 F1
K10 K8
X1
X1
X1
X1
Drawing 10.
031-300-190-039 Rev. D 2/16/06 190039_D

11.1 Wiring Schematic - TMS 870/ TTS 870
Drawing 11.1
031-300-190-039 Rev. D 2/16/06 190039_D

Drawing 11.2
031-300-190-039 Rev. D 2/16/06 190039_D
Drawing 11.3
031-300-190-039 Rev. D 2/16/06 190039_D
Drawing 11.4
031-300-190-039 Rev. D 2/16/06 190039_D
Drawing 11.5
031-300-190-039 Rev. D 2/16/06 190039_D

11.2 Wiring Schematic - RT 865 BXL
Drawing 12.1
031-300-190-039 Rev. D 2/16/06 190039_D
Drawing 12.2
031-300-190-039 Rev. D 2/16/06 190039_D
Drawing 12.3
031-300-190-039 Rev. D 2/16/06 190039_D


Optional Data Logger Connection
Drawing 12.4
031-300-190-039 Rev. D 2/16/06 190039_D

12. Boom Length Percentage Error

Boom length
percentage error
Keep the boom stop block

latched. Switch to Manual
Mode and retract the boom
completely.
Is the
percentage reading
(1%, 0%, 0%)? Yes
No
The LMI does not recognize the one or

more reset switch signals. Check
proximity switch target adjustment as Continue with section 13.
per section 9.1. If damage is visible
install new switch.
Measure voltage supply to IM switch at

terminal 1or 2 (+24V) and 5 or 6 (GND)
in the junction box at the front of the
boom base. Refer to section 9.1 and11.
Continue on next page
031-300-190-039 Rev. D 2/16/06 190039_D

12. Continuation
Continuation
Is the
No
voltage
correct?
Yes
Keep the inner mid section retracted.

Measure the inner mid reset switch signal Faulty voltage supply wiring to
at terminal 3 (24V) and 5 (GND) in the switch.Refer to section 11.
junction box at the front of the boom base Replace defective cables.
section. Refer to section 9.1 and 11.
Is the
No
voltage
correct ?
Yes
Measure the IM reset switch signal at

Defective IM reset switch.
terminal 5 (24V) and 9 (GND) in the length
Replace proximity switch.
sensor LG221. Refer to section 9.1 and 11.
031-300-190-039 Rev. D 2/16/06 190039_D

12. Continuation
Continuation
Is the
No
voltage
correct?
Yes
Measure the IM reset switch signal at Faulty wiring in cable

terminal 15 (24V) and 14 (GND) in the connecting the junction box
boom base junction box. Refer to with the length sensor. Refer to
section 9.1 and 11. section 11 to locate the fault.
Is the No
voltage
correct?
Yes
Faulty wiring in cable connecting

Measure the IM reset switch signal at central unit
the length sensor LG221 and the
terminal A104 80 (24V) and A 101 36 (GND).
boom base junction box. Refer to
Refer to section 9.3, 10 and 11.
section 11 to locate the fault.
031-300-190-039 Rev. D 2/16/06 190039_D

12. Continuation
Continuation
Is the
No
voltage
correct?
Yes
Measure the CM reset switch signal at

Defective CM reset switch.
terminal 10 (24V) and 9 (GND) in the length
Replace proximity switch.
sensor LG221. Refer to section 9.1 and 11.
Is the
No
voltage
correct ?
Yes
Measure the CM reset switch signal at Faulty wiring in cable connecting

terminal 30 (24V) and 14 (GND) in the the junction box with the length
boom base junction box. Refer to section sensor. Refer to section 11 to
9.1 and 11. locate the fault.
031-300-190-039 Rev. D 2/16/06 190039_D

12. Continuation
Continuation
Is the
No
voltage
correct?
Yes
Faulty wiring in cable

connecting the boom base
central unit terminal A114 9 (24V) and
junction box with the LG221.
A104 36 (GND). Refer to section 9.3,
Refer to section 11 to locate
10 and 11.
the fault.
Is the No
voltage
correct?
Yes
Faulty wiring in cable connecting

Measure voltage supply to OM switch at
the central unit and the boom
terminal 11 (+24V) and 9 (GND) in the center
base junction box. Refer to
mid junction box. Refer to section 9.1 and11.
section 11 to locate the fault.
031-300-190-039 Rev. D 2/16/06 190039_D

12. Continuation
Continuation
Is the
No
voltage
correct?
Yes

Measure voltage supply to CM switch at
connecting the central unit and
terminal 7 (+24V) and 5 (GND) in the inner
the boom base junction box.
mid junction box. Refer to section 9.1
and11.
the fault.
Is the
No
voltage
correct ?
Yes
Keep the outer mid (OM) section retracted.

Measure the OM reset switch signal at Faulty voltage supply wiring to
terminal 10 (24V) and 9 (GND) in the center switch.Refer to section 11.
mid junction box . Refer to section 9.1 Replace defective cables.
and 11.
031-300-190-039 Rev. D 2/16/06 190039_D

12. Continuation
Continuation
Is the
No
voltage
correct?
Yes

connecting the the center mid
terminal 10 (24V) and 9 (GND) in the
junction box and the LWG 221.
length- angle sensor LWG221. Refer to
section 9.1 and 11.
the fault.
Is the
No
voltage
correct ?
Yes
Measure the OM reset switch signal at Faulty wiring in cable connecting

terminal 17 (24V) and 14 (GND) in the the junction box with the length
boom base junction box. Refer to section sensor. Refer to section 11 to
9.1 and 11. locate the fault.
031-300-190-039 Rev. D 2/16/06 190039_D

12. Continuation
Continuation
Is the
No
voltage
correct?
Yes

Measure the OM reset switch signal at
connecting the boom base
central unit terminal A104 78 (24V) and
junction box with the LWG 221.
A104 36 (GND). Refer to section 9.3,
10 and 11.
the fault.
Is the No
voltage
correct?
Yes
Defective digital input 4, 5 on main board or Faulty wiring in cable connecting

digital input 5 on extension board. Contact the central unit and the boom
service dealer to obtain replacement base junction box. Refer to
instructions. section 11 to locate the fault.
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13. Main Boom Length Error

Main boom length error
In manual mode retract all

boom sections. Pull the boom
stop and retract the inner mid
section completely.
Is the Yes
main boom length
indicated correctly?
No
CAUTION: High tension on cable reel drum! Continue
CAUTION: To avoid length potentiometer damage, do not with B
turn the length potentiometer past the stop. on page 40
Is the
length cable No
spooled properly on
the LG 208
drum?
Yes
With all sections completely
retracted, un-spool the length
cable carefully. Let the drum
Reset the length potentiometer. Refer rewind slowly and spool the
to page 18 for instructions. cable manually back on the
drum. Check the roller guides
for correct adjustment. Refer to
section 9.1
031-300-190-039 Rev. D 2/16/06 190039_D

13. Continuation
Continuation
Has
the adjustment Yes
corrected the boom length
indication?
No
Check the power supply to the length sensor. Measure Continue

the power supply voltage at central unit terminal A104 with B
X1/11(-5V) and A104 X1/8(GND). on page 40
Is the voltage No
correct (-5V)?
Yes
Possible short or wiring fault between Main board component defective.

central unit and cable reel. Measure with Contact authorized service dealer
the DVM at the length transducer (LG 208) for the board replacement
terminal 1(GND) and 3(-5V) procedure.
031-300-190-039 Rev. D 2/16/06 190039_D

13. Continuation
Continuation
Is the voltage No
correct (-5V)?
Yes
Faulty wiring between

Verify the length sensor signal.
central unit and length
Measure the voltage at the length
transducer. Check
transducer (LG 208) terminal 1 (GND)
wiring, junction boxes
and 2 (-500mV) with fully retracted
and connectors for
boom.
faulty wiring.
No
Is the voltage
correct (-500mV)?
Yes
Defective length potentiometer.

Check the length signal in the central unit.
Replace length potentiometer
Measure the signal at central unit terminal
assembly. For instruction how to
A104 X1/10(-500mV) and A104 X1/8(GND)
change the length potentiometer
with fully retracted boom.
assembly refer to drawing on
Refer to section 11.
page 18.
031-300-190-039 Rev. D 2/16/06 190039_D

13. Continuation
Continuation
Yes
Is the voltage
correct (-500mV)?
No
Check the wiring that connects the Main board component defective.
LG 208 with the central unit. Inspect the Contact authorized service dealer for
cable and connectors. the board replacement procedure.
Yes
Have you found
any wiring faults?
No
Connect the voltmeter central unit Correct the wiring problem. Refer to
terminal A104 X1/10 (signal) and section 11.
A104 X1/8 (GND). Use a small
screwdriver to turn the length
potentiometer carefully clockwise.
The voltage should decrease
from -500mV to -4.5V.
Continue on next page B
031-300-190-039 Rev. D 2/16/06 190039_D

13. Continuation
Continuation
Is
the voltage Yes
decreasing from
-500mV to
-4.5V ?
No
Check the wiring between length Main board component defective.

transducer LG 208 and central unit. Contact authorized service dealer for
Inspect cable connectors and junction main board replacement procedure.
boxes .
Have you found Yes

any wiring faults?
No
Connect the voltmeter to terminal 2

(signal) and terminal 1 (GND) in the
cable reel. Carefully turn the length
Correct the wiring problem. Refer to
potentiometer clockwise. Use a
section 11.
small screwdriver to avoid damage.
The Voltage should decrease
from -500mV to -4.5V.
031-300-190-039 Rev. D 2/16/06 190039_D

13. Continuation
Continuation
Is the
voltage correct? Yes
[O turns = - 500mV
10 turns= - 4.5V]
No
Defective length potentiometer assembly. Replace and

Refer to page 18 and reset length
adjust length potentiometer. Refer to drawing on page
transducer. Continue with section 14.
18.
031-300-190-039 Rev. D 2/16/06 190039_D

14. Inner Mid Length Error
Inner mid length error

section completely.
Is the Yes
inner mid boom length
indicated correctly?
Continue
No with B
on page 46
CAUTION: High tension on cable reel drum!
CAUTION: To avoid length potentiometer damage, do not
turn the length potentiometer past the stop.
Is the
length cable No
spooled properly on
the LG 221
drum?
With all sections completely

Yes
Reset the length potentiometer. rewind slowly and spool the
Refer to page 18 for instructions. cable manually back on the
section 9.1
031-300-190-039 Rev. D 2/16/06 190039_D

14. Continuation
Continuation
Yes
Has
the adjustment
corrected the inner mid
length indication?
No

Is the voltage No
correct (-5V)?
Yes

the DVM at the length transducer (LG 221) for the board replacement
terminal 1(GND) and 3(-5V) procedure.
031-300-190-039 Rev. D 2/16/06 190039_D

14. Continuation
Continuation
Is the voltage No
correct (-5V)?
Yes

transducer. Check
transducer (LG 221) terminal 1 (GND)
and 2 (-500mV) with fully retracted
and connectors for
boom.
faulty wiring.
No
Is the voltage
correct (-500mV)?
Yes

A104 X1/24 (-500mV) and A104 X1/8
assembly. Refer to drawing on
(GND) with fully retracted boom.
page 18.
031-300-190-039 Rev. D 2/16/06 190039_D

14. Continuation
Continuation
Yes
Is the voltage
correct (-500mV)?
No
LG 221 with the central unit. Inspect the Contact authorized service dealer for
cable and the connections. the board replacement procedure.
Yes
Have you found
any wiring faults?
No
Connect the voltmeter to central unit

terminal A104 X1/24(signal) and Correct the wiring problem. Refer to
A104 X1/8 (GND). section 11.
Use a small screwdriver to turn the length
potentiometer carefully clockwise.
O turns = - 500mV, 10 turns= - 4.5V.
031-300-190-039 Rev. D 2/16/06 190039_D

14. Continuation
Continuation
Is
the voltage Yes
decreasing from
-500mV to
-4.5V ?
No
Check the wiring between length

transducer LG 221 and central unit. Main board component defective.
Inspect cable connectors and junction Contact authorized service dealer for
boxes . main board replacement procedure.
Have you found

any wiring faults?
Yes
No

cable reel. Carefully turn the length Correct the wiring problem. Refer to
potentiometer clockwise. Use a small section 11.
screwdriver to avoid damage.
O turns = - 500mV, 10 turns= - 4.5V.
031-300-190-039 Rev. D 2/16/06 190039_D

14. Continuation
Continuation
Is the
[O turns = - 500mV
10 turns= - 4.5V]
No
Defective length potentiometer Refer to page18 and reset length

assembly. Replace and adjust length transducer. Possible main board defect.
potentiometer. Refer to drawing on Contact authorized service dealer for
page 18. further assistance.
031-300-190-039 Rev. D 2/16/06 190039_D

15. Center Mid Length Error
Center mid length error

section completely.
Is the Yes
center mid
length indicated
correctly?
No Continue
with B
on page 52
CAUTION: High tension on cable reel drum!
CAUTION: To avoid length potentiometer damage, do not
turn the length potentiometer past the stop.
Is the
length cable No
spooled properly on
the LWG 221
drum?
Yes With all sections completely

Reset the length potentiometer. rewind slowly and spool the
Refer to page 18 for instructions. cable manually back on the
section 9.1
031-300-190-039 Rev. D 2/16/06 190039_D

15. Continuation
Continuation
Has
the adjustment Yes
corrected the center mid
length indication?
No

Is the voltage No
correct (-5V)?
Yes

the DVM at the length transducer for the board replacement
(LWG 221) terminal 1(GND) and 3(-5V). procedure.
031-300-190-039 Rev. D 2/16/06 190039_D

15. Continuation
Continuation
Is the voltage No
correct (-5V)?
Yes

transducer. Check
transducer (LWG 221) terminal 1
(GND) and 2 (-500mV) with fully
and connectors for
retracted boom.
faulty wiring.
No
Is the voltage
correct (-500mV)?
Yes

A104 X1/73 (-500mV) and A104 X1/8
assembly. Refer to drawing on
(GND) with fully retracted boom.
page 18.
031-300-190-039 Rev. D 2/16/06 190039_D

15. Continuation
Continuation
Yes
Is the voltage
correct (-500mV)?
No
LWG 221 with the central unit. Inspect Contact authorized service dealer for
the cable and the connections. the board replacement procedure.
Yes
Have you found
any wiring faults?
No
Connect the voltmeter central unit terminal

Correct the wiring problem. Refer to
A104 X1/73 (signal) and A104 X1/8
section 11.
(GND). Use a small screwdriver to turn the
length potentiometer carefully clockwise.
O turns = - 500mV, 10 turns= - 4.5V.
031-300-190-039 Rev. D 2/16/06 190039_D

15. Continuation
Continuation
Is
the voltage Yes
decreasing from
-500mV to
-4.5V ?
No
Check the wiring between length

transducer LWG 221 and central unit. Main board component defective.
Inspect cable connectors and junction Contact authorized service dealer for
boxes . main board replacement procedure.
Have you found

any wiring failures?
Yes
No

cable reel. Carefully turn the length Correct the wiring problem. Refer to
potentiometer clockwise. Use a small section 11.
screwdriver to avoid damage.
O turns = - 500mV, 10 turns= - 4.5V.
031-300-190-039 Rev. D 2/16/06 190039_D

15. Continuation
Continuation
Is the
[O turns = - 500mV
10 turns= - 4.5V]
No
Defective length potentiometer

Possible main board defect. Contact
assembly. Replace and adjust length
authorized service dealer for further
potentiometer. Refer to drawing on
assistance.
page 18.
031-300-190-039 Rev. D 2/16/06 190039_D

16. No Extend or Retract Function in Automode
Boom does not extend or retract

in automode.
Switch to manual mode and extend or

retract the boom manually.
Does the No
boom extend or
retract?
Yes
Switch to automode. Start the engine and operate the Defect in crane electric or hydraulic circuit.
extend control. Measure the voltage at central unit Reset crane fuse breaker. Check LMI fuses
terminal A104 X1/38 (24V) and A104X1/37 (GND) while in the central unit enclosure. Refer to
operating the extend control. section 9.3, 10.1 and 10.2.
Is the voltage correct?

No
Yes
Faulty wiring to extend pressure switch or

Continue on next page defective pressure switch. Correct the
wiring and replace the switch if defective.
031-300-190-039 Rev. D 2/16/06 190039_D

16. Continuation
Continuation
Switch to automode. Start the engine and operate the

retract control. Measure the voltage at central unit
terminal A104 X1/40 (24V) and A104 X1/39 (GND)
while operating the extend control.
No
Is the voltage correct?
Yes
Select the service screen on the

Faulty wiring to retract pressure switch or
console by pressing the two outer keys to the left of the
defective pressure switch. Correct the
LCD simultaneously. The ramping value for the selected
wiring and replace the switch if defective.
section shall increase from 0 to 255. The ramping value
remains 0 in neutral position.
Is the No
ramping value
increasing?
Yes
Continue to troubleshoot the wiring to Check ribbon cable connection in

the 2 way valve and the hydraulic central unit and wiring in the
circuit. Refer to Grove documentation. central unit.
031-300-190-039 Rev. D 2/16/06 190039_D

17. Out of Sequence Warning
Boom sections are out of

sequence (Automode).
Follow the instruction in

section 12.
Is the problem Yes

corrected?
No
Follow the instruction in End

section 13.
Is the problem Yes

corrected?
No
Continue on next page End
031-300-190-039 Rev. D 2/16/06 190039_D

17. Continuation
Continuation

section 14.
Is the problem Yes

corrected?
No

End
section 15.
Is the problem
corrected? Yes
No
Continue on next page End
031-300-190-039 Rev. D 2/16/06 190039_D

17. Continuation
Continuation
With outer mid section completely retracted

check the adjustment for the OM retract
switch target. Refer to section 9.1.
Is the
switch and No
target adjusted
correctly?
Yes
Measure switch signal at central

unit terminal Adjust OM retract
A104 X1/ 76 (24V) and switch and target.
A104 X1/ 36 (GND).
Is the Yes
voltage
correct?
No
Main board component defective.

Continue on next page Contact authorized service dealer for
main board replacement procedure.
031-300-190-039 Rev. D 2/16/06 190039_D

17. Continuation
Continuation
Faulty wiring. Check the voltage at terminal

17 (24V) and 13 (GND) in boom base
junction box. Refer to section 9.and 11.
Have you Yes

located a wiring
fault?
No
Correct the wiring

Measure switch signal at
between boom base
LWG 221 terminal 10 (24V)
junction box and central
and 9 (GND).
unit. Refer to section 11.
Is the Yes
voltage
correct?
No
Correct the wiring between LWG 221

Continue on next page and boom base junction box. Refer to
section 9. and 11.
031-300-190-039 Rev. D 2/16/06 190039_D

17. Continuation
Continuation
Check the signal at terminal 10 (24V) and

9 (GND) in CM junction box. Refer to section 9.1 and 11.
Is the No
voltage
correct?
Yes
Retract all boom section in Defective OM retract

manual mode and let the switch. Replace
system reset boom percentage. proximity switch. Refer
Recheck. to section 9. and 11.
End
031-300-190-039 Rev. D 2/16/06 190039_D

18 Error Codes
Error Code Error Cause Elimination

E01 Fallen below x Fallen below the minimum x Luff down the boom to a
radius range or radius or gone past the radius or angle specified in
maximum angle specified in the the load chart.
angle range respective load chart due to
exceeded luffing up the boom too far
E02 Radius range x Gone past the maximum radius x Luff up the boom to a radius
exceeded or fallen or fallen below the minimum or angle specified in the load
angle specified in the chart.
below angle range respective load chart due to
luffing down the boom too far
E03 Non-permitted x The slewing zone with load is x Slew to permitted area
slewing zone (no not permitted
load area)
E04 Operating mode x A non existing operating mode x Set the correct operating
not acknowledged has been selected mode for the operating state
in question
or non permitted
slewing zone
x The boom is in a non-permitted x Slew the boom to a
slewing zone permitted area.
E05 Prohibited length x Boom has been extended x Extend/retract boom to the
range either too far or not far enough, correct length
e.g. if it is prohibited to go
beyond a certain maximum
boom length or with load
curves for jibs where the main
boom has to be extended to a
certain length
x Length sensor adjustment has x Retract boom. Check the
changed, e.g. the cable slid off prestress of the cable reel
the length sensor reel. (cable must be taut). Open
the length sensor and
carefully turn the length
sensor pot counterclockwise
until the detent by means of
a screw driver
x Clutch between length sensor x Replace the complete clutch
pot and drive is defective including drive wheel and
adjust length sensor pot as
described above
x Failure of +5V supply of analog x Check +5 V supply.
part of analog board Exchange main board in
case of voltage failure or
breakdown when loaded
with 50 ohms approx.
x Cable between central unit and x Check cable and plugs,
length sensor is defective or replace, if need be.
disconnected.
x Defective length potentiometer x Replace length
potentiometer.
031-300-190-039 Rev. D 2/16/06 190039_D

E06 Radius range x Maximum radius as specified in x Luff the jib to a radius or
exceeded or fallen the load chart exceeded or angle specified in the load
fallen below minimum angle chart.
below angle range due to luffing down the luffing
with luffing jib jib too far
operation
E07 Faulty x Overload relay or connection x Replace connection board
acknowledgment board are defective
of the overload
x Processor board defective
relay on the x Replace processor board.
connection board.
The relay should
be energized, the
2nd contact
however is
indicated to be off,
or the 2nd contact
is indicated to be
on while the relay
should be de-
energized.
E08 No x refer to E07 x refer to E07
acknowledgment
from the anti-two-
block relay
E10 Error in the length x With the boom retracted, the x Check length sensor of the
measurement signal "main boom length" main boom
differs by more than 2 % from
the programmed value for the
basic length
x With the boom retracted, the x Check length sensor 2.
signal "length Tele I (+II)"
differs by more than 2 % from
the reference value 0
031-300-190-039 Rev. D 2/16/06 190039_D


E11 Fallen below lower x Cable between central unit x Check cable as well as
limit value for and length sensor is plugs, replace, if need be.
defective or disconnected.
measuring Water inside the plug of the
channel "length length/angle sensor
main boom"
x Length potentiometer is x Replace length
defective potentiometer
x Electronic component in the x Replace LMI main board or
measuring channel is processor board.
defective
E12 Fallen below the x Cable between the central x Check cable as well as
lower limit value in unit and pressure plugs, replace, if need be.
transducers defective or
the measuring water inside the plugs
channel "pressure
piston side"
x Pressure transducer is x Replace pressure

defective. transducer
defective.
E13 Fallen below lower x refer to E12 x refer to E12
limit value in the
measuring
channel "pressure
rod side"
E14 Fallen below lower x Cable between the central x Check cable as well as
limit value in unit and pressure plugs, replace, if need be.
transducers defective or
measuring water inside the plugs
channel "force"
x Force transducer defective x Replace force transducer

defective.
E15 Fallen below lower x Cable between central unit x Check cable as well as
limit value in and the length/angle sensor plugs, replace, if need be.
defective or loose. Water
measuring inside the plug of the
channel "angle length/angle sensor.
main boom"
x Angle potentiometer x Replace angle sensor

defective
measuring channel processor board.
defective.
031-300-190-039 Rev. D 2/16/06 190039_D


limit value in unit and the angle sensor plugs, replace, if need be.
measuring inside the plug of the angle
channel "angle 2" sensor.

defective
defective.
limit value "length unit to the length sensor plugs, replace, if need be.
telescope I (+II)" inside the length sensor
plug.
x Length potentiometer x Replace length sensor.
defective
measuring channel defective processor board.
E18 Front outrigger x Front outrigger overloaded x
overloaded
E19 Reference and/or x The supply voltage is x Check the voltages on the
supply voltage falsified by one of the LMI main board (AGND =
sensors (DAV, LWG) MP0). Check sensors, plugs
defective and cable, replace, if need
be.
x Electronic component is x Replace LMI main board
defective
x A/D converter defective. x Replace LMI main board
E1A Fallen below lower x Cable between the central x Check cable as well as
limit value in unit and the slewing angle plugs, replace, if need be.
sensor defective or loose.
measuring Water inside the plug of the
channel "slewing angle sensor
angle 1".
x Slewing angle potentiometer x Replace slewing angle

is defective sensor
E1B Fallen below lower x refer to E1A x refer to E1A
limit value in
measuring
channel "slewing
angle 2"
031-300-190-039 Rev. D 2/16/06 190039_D


E1D Fallen below lower x Cable between the central x Check cable as well as
limit value "length unit to the length sensor plugs, replace, if need be.
telescope 3" inside the length sensor
plug.
x Length potentiometer x Replace length sensor.
defective
E1E Fallen below lower x Cable between the central x Check cable as well as
limit value in unit and the angle sensor plugs, replace, if need be.
measuring inside the plug of the angle
channel "boom sensor.
head angle"

defective
defective.
E21 Upper limit value x refer to E11 x refer to E11
in measuring
channel "main
boom length" has
been exceeded.
in measuring
channel "pressure
piston side" has
been exceeded
in measuring
channel "pressure
rod side" has
been exceeded.
in measuring
channel "force"
has been
exceeded.
in measuring
channel "main
boom angle" has
been exceeded.
031-300-190-039 Rev. D 2/16/06 190039_D


in measuring
channel "angle 2"
has been
exceeded.
in measuring
channel "length
telescope I (+II)
has been
exceeded.
E29 Reference and/or x refer to E19 x refer to E19
supply voltage
defective.
E2A Upper limit value x refer to E1A x refer to E1A
in measuring
channel "slewing
angle 1" has been
exceeded
E2B Upper limit value x refer to E1A x refer to E1A
in measuring
channel "slewing
angle 2" has been
exceeded
E2D Upper limit value x refer to E1D x refer to E1D
in measuring
channel "length
telescope 3 has
been exceeded.
E2E Upper limit value x refer to E1E x refer to E1E
in measuring
channel " boom
head angle" has
been exceeded.
E31 Error in the x The system program PROM x Replace system program
system program is defective. PROM (PROM No. 0)
E38 System program x The system program in the x Replace the system
and data EPROM LMI does not match to the program PROM or the data
programming in the data EPROM (PROM No. 1)
do not match. EPROM
031-300-190-039 Rev. D 2/16/06 190039_D


E39 System program x The system program in the x Replace system program
and TLK EPROM LMI and the programming in PROM or TLK EPROM
the TLK EPROM do not (PROM No. 2).
do not match match.
E41 Error in the x Computer component x Replace computer

internal write/read 80C537 defective component 80C537.
memory (RAM) of
the computer x CPU module defective x Replace CPU module.
component
x Processor board defective. x Replace processor board
80C537 with CPU module.
E42 Error in the x Write/read memory (CMOS x Replace processor board
external write/read RAM) or processor board with CPU module.
defective.
memory, 1st part
(RAM)
E43 Error in the x refer to E42 x refer to E42
external write/read
memory, 2nd part
(RAM)
E45 Redundancy error x The A/D converter on the x Replace processor board.
in the A/D processing board and the
redundant A/D converter in
conversion the CPU 80C537 provide
different results.
E46 Error in the A/D x No acknowledgment of the x Replace processor board.
converter uPD A/D converter uPD 7004
7004 of the
processor board.
E47 Error in the x The CRC sign of the x Restart the LMI
monitored write/ monitored write/read
memory is wrong
read memory.
x The buffer battery is x Replace buffer battery on
The CRC decharged (< 2V at 1kOhm).
verification of the the LMI main board
monitored
write/read x Processor board defective. x Replace processor board.
memory provides
an incoherent
result
031-300-190-039 Rev. D 2/16/06 190039_D


E48 Cyclic RAM test: x Computer component x Replace computer
error in the 80C537 defective component 80C537.
internal write/read
memory (RAM) of x CPU module defective x Replace CPU module
the computer
x Processor board defective. x Replace processor board
component with CPU module.
80C537
E51 Error in the crane x No valid data in the crane x Load crane data EEPROM
data EPROM or data EEPROM. containing valid data.
EEPROM.
x Memory module wrongly x Bridge memory module acc.
bridged. to memory type
x Crane data EPROM x Replace crane data EPROM

defective
E52 Error in load chart x Memory module wrongly x Bridge memory module acc.
PROM. bridged. to memory type.
x Load chart EPROM x Replace load chart EPROM

defective.
E56 Error in crane x Memory module wrongly x Bridge memory module acc.
data EEPROM. bridged. to memory type
x Crane data EEPROM x Replace crane data

defective EEPROM
E57 Error in serial x Serial crane data EEPROM x Write data on the serial
crane data does not contain valid data. crane data EEPROM (by
means of test program or
EEPROM. on-line function), then restart
the LMI
x Memory module defective x Replace memory module.
E58 Error in the serial x No valid data in the serial x Write data on the serial
analog data analog data EEPROM. analog data EEPROM by
means of the test program,
EEPROM. then, restart the LMI
x LMI main board defective. x Replace LMI main board.
031-300-190-039 Rev. D 2/16/06 190039_D


E60 The number of the x Load chart EPROM x Replace load chart EPROM
selected EPROM defective
base and the
programmed
value are not
identical
x Base number not x Program the correct base
programmed number (1 for base 1, 2 for
base 2)
x Load chart EPROM wrongly x Check base programming in
programmed the load chart EPROM.
E61 Error in the boom x Cable between the central x Check the cable to the boom
control extension. unit and the boom control control extension
extension defective.
x Profibus adapter in the x Replace the profibus
central unit defektiv adapter
x Profibus adapter in the x Replace the profibus
Boom control extension adapter
defective
E62 Error digital inputs x Module for digital inputs in x Replace the module for the
1 - 8 in the boom the Boom control extension digital inputs
defective
control extension.
x Boom control extension x Replace the boom control
defective extension
E63 Error digital inputs x Module for digital inputs in x Replace the module for the
9 - 16 in the boom the Boom control extension digital inputs
defective
control extension.
defective extension
E64 Error analog x Module for analog output 1 x Replace the module for the
output 1 in the in the Boom control analog output 1
extension defective
boom control
extension.
defective extension
E65 Error analog x Module for analog output 2 x Replace the module for the
output 2 in the in the Boom control analog output 2
extension defective
boom control
extension.
defective extension
031-300-190-039 Rev. D 2/16/06 190039_D


E66 Error analog x Module for analog outputs in x Replace the module for the
outputs in the the Boom control extension analog outputs
defective
boom control
extension.
defective extension
E70 Error relay outputs x Module for relay outputs in x Replace the module for the
in the boom the Boom control extension relay outputs
defective
control extension.
defective extension
E71 Faulty x Relay K1 or connection x Replace connection board.
acknowledgment board defective.
of relay K1 on the
connection board
Relay should be x LMI main board is defective x Replace LMI main board.
energized but the
2nd contact is
signaled to be off
or the 2nd contact
is signaled to be
on whereas the
relay should be
de-energized.
E72 Faulty x refer to E71 x refer to E71

... acknowledgment
E77 of relays K2...K7
on the connection
board.
E81 Too large x The angle as to the x Check angle sensor on the
difference of the horizontal on the boom head boom head.
boom angles at tip exceeds the main boom x Check angle sensor on the
angle by more than 5 base boom.
and base boom. degrees.
E83 Center Mid not x The Center Mid is not on ist x Extend the Center Mid
fully extended fully extended position while
the OM/Fly is not completly x Retract the OM/Fly
retracted
x Check the OM/Fly switch
(digital input 4)
E84 Wrong rigging x The selected rigging x Select another rigging
condition. condition is not contained in condition
the data EPROM.
x Check the programming in
the data EPROM.
031-300-190-039 Rev. D 2/16/06 190039_D

E85 Error in the radius x The computed radius is too x Check the programming in
determination small (negative deflection) the data EPROM.
x Check the length

measurement system.
E89 Operating mode x The operating mode on the x Select operating mode
switchover with console has been switched without load on the boom
over with the boom loaded.
load.
E91 No data trans- x 24 V supply of the console is x Check 24 V at terminal X1 of
mission form the interrupted the console electronics
console to the
central unit
x Interruption or accidental x Check the connection
ground in the line between console electronics - central
console electronics and unit. In case of an accidental
central unit ground, the transmitter
module of the console
electronics might be
damaged. Therefore,
replaces the console
electronics.
x Transmitter/receiver module x Exchange console
is defective electronics or LMI main
board resp.
E92 Error in the data x Loose connection in the line x Check the connection
transmission from between console electronics between console electronics
and central unit and central unit
console to central
x Transmitter/receiver module x Exchange console
unit is defective electronics or LMI main
board resp.
E93 Error in the data x refer to E92 x refer to E92
transmission from
the central unit to
the console
E94 No data trans- x Interruption or accidental x Check line to the console (in
mission from the ground in the line central case of accidental ground,
unit - console replace console electronics,
central unit to the too).
console
x 5 V supply of the computer x Check connection to the
in the central unit is missing power unit
x 5 V supply is too low x Exchange the LMI main
board
x Transmitter/receiver module x Replace console electronics
is defective or LMI main board
x Computer module is x Replace processor board.
defective
031-300-190-039 Rev. D 2/16/06 190039_D


E94 cont’ x Electro-magnetic x Eliminate the source of
interferences (e.g. when interferences by inverse
switching contactors or diodes or varistors.
valves)
E95 Error in the x The console EPROM is x Replace the console

console EPROM defective. EPROM
E96 Error in the x The CPU of the console is x Replace the CPU of the
internal RAM of defective. console
the console.
x The console main board is x Replace the console main
defective. board.
E97 Error in the x The external RAM of the x Replace the external RAM
external RAM of console is defective. of the console.
the console
x The console main board is x Replace the console main
defective. board.
EAB Short circuit in the x Short circuit in the A2B x Replace A2B switch
A2B switch circuit switch
x Short circuit in the cable to x Replace cable to the A2B

the A2B switch switch
Note:
If an error message is displayed which is not contained in above list, please contact the
Hirschmann Service Department.
031-300-190-039 Rev. D 2/16/06 190039_D

DS350G Boom Control Service AC 120

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SERVICE MANUAL (TMS/TTS870, RT865BXL)

031-300-190-039 Rev. D 2/16/06 190039_D

No part of this document may be photocopied, reproduced, or translated to another language

All information in this document is subject to change without notice.

REV DATE NAME DESCRIPTION

031-300-190-039 Rev. D 2/16/06 190039_D

Section Content Page

031-300-190-039 Rev. D 2/16/06 190039_D

Parts & Installation Manual:

Crane Model PAT- Part number Grove- Part number

PAT - Part number

031-300-190-039 Rev. D 2/16/06 190039_D

4. Service and Maintenance

Daily maintenance of the load moment indicator consists of inspecting:

1. The electrical wiring connecting the various parts of the system.

3. Check the anti two-block limit switches for freedom of movement.

4. The cable reel shall be under tension to operate properly.

031-300-190-039 Rev. D 2/16/06 190039_D

House lock switch (EEC units) *

031-300-190-039 Rev. D 2/16/06

technical modification without prior notice.

Inner mid length sensor

Main boom length sensor

Main boom angle sensor

Piston pressure transducer

870 - LMI (751)

Auto mode / Manual mode:

Pilot pressure switch signal / Analog output signal:

031-300-190-039 Rev. D 2/16/06 190039_D

Disengage the boom stop to retract the boom completely.

Inner mid retract and % reset switch:

031-300-190-039 Rev. D 2/16/06 190039_D

Center mid retract and % reset switch:

Outer mid/ fly retract and % reset switch:

DI # Description Central Unit Signal

Note: MB = main board * = RT 865 BXL only

031-300-190-039 Rev. D 2/16/06 190039_D

Output for two- way valves:

Mode Relay K2 IM 2 way Relay K6 CM 2 way Relay K7 OM 2 way

Relay Fuse Description Central Unit Signal

031-300-190-039 Rev. D 2/16/06 190039_D

Rod side dump valve:

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7. Boom Control Flow

B.C.S. checks input for Operation in manual

B.C.S. checks input for

031-300-190-039 Rev. D 2/16/06 190039_D

The B.C.S. relays K2,

The B.C.S. relay K3

The B.C.S. analog

While estending and

Out of sequence warning and lock

031-300-190-039 Rev. D 2/16/06 190039_D

Max. Ramp Ramp down Max. Ramp

Min. Ramp Boom

IM: Inner Mid Section

031-300-190-039 Rev. D 2/16/06 190039_D

9.1 DS 350 G - Boom Components and Setup

031-300-190-039 Rev. D 2/16/06 190039_D

Partial top view

This proximity switch

031-300-190-039 Rev. D 2/16/06 190039_D

9.2 Length Transducer Adjustment